Shindaiwa SWF500K User manual

OWNER’S AND OPERATOR’S MANUAL
Wire Feeder
SWF500K
SWF500K
X753-008 77 0
X753803-460 0
CAUTION
Do not operate the Generator/Welder, or any other appliance, before you have
read and understood the instructions for use and keep near for ready use.

Introduction
We would like to thank you very much for purchasing this Shindaiwa wire feeder.
 This manual has been created in order to ensure safe and proper use of this
equipment. Be sure to thoroughly read this manual before operating the equipment as
the improper operation of this equipment can result in an accident or malfunction.
 This equipment should only be operated by persons who thoroughly understand the
contents of this manual and can safely operate the equipment. Persons who are ill,
taking medicine, or are in bad health should not operate this equipment if such
conditions will affect operation of the equipment and related work.
 Operation and use of this equipment must be in strict compliance with the applicable
laws, as well as rules and regulations based on such laws.
 Always be sure to include this manual with the equipment if it is loaned out to another
party, and instruct said party that they must thoroughly read this manual before
operating the equipment.
 Store this manual securely in a predetermined location so that it can be readily
accessed at all times to order parts or arrange for repair. Contact the retail outlet where
this equipment was purchased if any parts are lost, the equipment becomes soiled, or
is otherwise damaged in any manner.
 Consult with the retail outlet where the equipment was purchased if any of the points
are unclear or you would like further information.
Be sure to note the model name and serial number of your equipment, and provide this
information when making an inquiry.
 If disposing of this equipment, dispose in a manner according to laws and regulations
applicable to industrial waste. Consult with the retail outlet where the equipment was
purchased if you have any inquiries regarding proper disposal.
 The precautions used in this manual are divided into the following three ranks.
 It is possible that items described under < Caution > or < Note > can result in a
serious accident depending on the circumstances. The contents of both of these types
of precautions are important. Be sure to always comply with all precautions.
Warning: Improper operation can result in death or serious personal injury.
Caution: Improper operation can result in moderate or minor personal injury,
or physical damage.
<Note>: Explanatory note in order to ensure that equipment protection and
performance are fully realized.

- 1 -
Table of Contents
1. Safety Precautions ........................................................................... 2
2. Specifications ................................................................................... 5
3 Application ........................................................................................ 5
4. Part Names ........................................................................................ 5
5. Pre-Operation Inspection ................................................................ 7
6. Preliminary Preparation for Welding .............................................. 8
6-1. Welding Cable Selection........................................................... 8
6-2. Welding Polarity ........................................................................ 8
6-3. Welding Cable Connection ....................................................... 9
6-4. Feed Roller Replacement ....................................................... 10
6-5. Gun Connection ...................................................................... 10
6-6. Wire Setting ............................................................................ 10
6-7. Spool Brake Adjustment ......................................................... 11
6-8. Pressure Arm Adjustment ....................................................... 11
6-9. Duty Cycle ............................................................................... 11
7. Welding Work .................................................................................. 12
7-1. Display .................................................................................... 13
7-2. Wire Feed Speed Adjustment ................................................. 14
7-3. Voltage Control ........................................................................ 14
7-4. Wire Feed Speed Selector Switch .......................................... 14
7-5. CC/CV Switch ......................................................................... 14
7-6. Wire Feed Button .................................................................... 15
7-7. 2 STEP-Trigger Interlock Switch ............................................ 15
7-8. Soft Start Switch...................................................................... 15
7-9. m/inch Selector Switch ........................................................... 15
7-10. Monitor Display ....................................................................... 15
8. Troubleshooting ............................................................................. 16
9. Wiring Diagram ............................................................................... 18

- 2 -
Warning: Suffocation from Welding Fume
 Always be sure to wear a fume-proof mask when welding as the fumes generated
during welding include harmful gases and dust. Also be careful that the wind direction
is not such that it will cause fumes to be inhaled and always operate the equipment in
a well-ventilated area.
Warning: Electric Shock
 Close the door of this wire feeder while welding.
 Do not touch this wire feeder if it or any of your body part is wet.
 Touching a charged part may result in lethal electric shock or burns.
 Do not touch the charged part of the wire, wire-feeding parts, or similar charged parts
while performing welding work.
 Be sure to always stop the welder when installing/removing welding cables to/from
the welder, and when replacing the wire and feed rollers.
 Never connect a welding cable to any part other than the welding output terminals of
the welder.
 Always be sure to stop the welder when performing inspection or maintenance.
Warning: Fire
 Keep any ignitable items (such as fuel, gas and paint) or inflammable items away
from the work area due to the scattering of weld spatter that occurs during welding.
Warning: Injury
 Do not place hands inside the wire feeder while operating. You could be caught in the
wire feeding rollers.
 Do no perform inching or pull the torch switch when your eyes, face, or body is near
the welding torch tip because it may result in injury from the tip of the welding wire.
 Do not use this wire feeder if it has been modified or any part has been removed.
Warning: Electromagnetic Interference
 Persons using a heart pacemaker are not allowed near the welder or welding work
area while welding is being performed without the permission of a doctor. The welder
generates a magnetic field while energized that can negatively affect pacemaker
operation.
Caution: Electric Shock
 Do not sprinkle water on the equipment and do not use where exposed to rain.
 If wearing gloves, be sure to always wear gloves with dry insulation properties. Do not
wear gloves that are damaged or wet.
Caution: Burns
 Always be sure to wear leather gloves, apron, shoe covers, arc-proof glasses (face
shield), safety shoes, hard hat and long-sleeve clothing to protect against the
scattering of weld spatter that occurs during welding.
1. Safety Precautions

- 3 -
Caution: Injury to Eyes and Skin
 Always be sure to wear arc-proof glasses, clothes that completely cover the skin and
other protective gear when welding to protect the eyes and skin from harmful light
rays generated during welding.
Caution: Physical and Secondary Damage
 Do not use the equipment for any improper applications. Improper usage can result in
an accident or malfunction.

- 4 -
 Location of Warning Labels
Replace warning labels when they become difficult to see or damaged by affixing
new labels in the specified locations. Order the necessary labels by numbers in
parentheses.
 Suffocation from Welding Fume (No. X564-000940)
 Electric Shock (No. X564-000950)
 Electric Shock (No. X564-000960)
 Injury (No. X564-000970)
Inside Cabinet

- 5 -
Input voltage Normal (V)
DC 15－110
External source (V)
AC 24－42
Rated welding current
Duty cycle: 60% (A) 500
Duty cycle: 100% (A) 340
Wire feeding speed Inch display (inch/min)
50－700
Meter display (m/min)
1.3－17.8
Applicable wire
diameter
GMAW
(Solid or Cored Wires)
(mm)
φ1.2
(Optional)
φ0.9, 1.6
FCAW
(Self-Shielded Wires) (mm)
φ0.9, 1.2, 1.4, 1.6, 1.8, 2.0, 2.4
Spool shaft
Shaft diameter (mm) 50
Max. installation width (mm) 105
Max. installation diameter (mm) 300
Brake mechanism Equipped
Weight (kg) 16
Length (mm) 555
Width (mm) 221
Height (mm) 428
 Semi-automatic Arc Welding(MIG, MAG, Self-Shielded)
Caution: Physical and Secondary Damage
 Do not use this wire feeder for any purposes other than that indicated above.
Improper usage can result in an accident or malfunction.
Wire Feed Speed
Dial
2. Specifications
4. Part Names
Work Clip
Voltage Control Dial
Gun Trigger
Connector
Gun Connection
Wire Feed Speed
Selector Switch
3. Application
Gas Outlet

- 6 -
Wire Feed
Speed Lamp
Welding Cable
Motor Overload
Lamp
Wire Feed Speed/Amperage
Meter
Welding Voltage
Meter
Overheating Lamp
Voltage Lamp
Current Lamp
Spool Shaft
Pressure
Arms
Spool
Retainer
14-Pin Plug
Inside Cabinet
Gas Inlet

- 7 -
Warning: Electric Shock
 Always be sure to stop the welder when performing inspection.
Inspection
Location Inspection Item Comments
Wire Feeding
Unit

Check that the diameter of the welding
wire matches or conforms to the
nominal diameter of the rollers
The nominal diameter is
inscribed on the rollers
 Check roller grooves for clogging,
chipping, and groove wear
Can cause poor wire
feeding
 Check for looseness of knurled screws
fixing rollers (4 locations) Can cause parts falling off

Check for chips or foreign material
accumulated near the gun inlet and
rollers
Can cause clogged torch
cable
Welding Torch
 Insertion of welding gun terminal Check that terminals are
fully inserted
 Check for looseness of screws fixing
the welding gun
Check that screws are
securely fixed
 Welding tip consumption and wear Can cause poor welding
performance
2 STEP-Trigger
Interlock Switch
Soft Start Switch
CC/CV Switch
Wire Feed Button
m/inch Selector Switch
Accessories
OWNER’S
AND
OPERATOR’S
MANUAL
5. Pre-Operation Inspection

- 8 -
6-1. Welding Cable Selection
Use welding cables with a cross-sectional area that is larger than the proper
cross-sectional areas indicated in the table below.
Using cable that is less than the proper cross-sectional area reduces the weld output.
<Note>
 Use welding cables when they are completely extended (not coiled). Using a cable
that is coiled reduces the weld output.
Proper Cable Cross-Sectional Area (Units: mm2)
Return Length
Weld Current 20m
30m 40m 60m 80m 100m
500A 38 60 80 125 200 200
450A 38 60 80 100 150 200
400A 38 50 60 100 125 200
350A 30 50 60 80 125 150
300A 30 38 50 80 100 125
250A 22 30 38 60 80 100
200A 22 30 30 50 60 80
150A 22 22 22 38 50 60
100A 22 22 22 30 30 38
6-2. Welding Polarity
There are "＋" (positive) and "－" (negative) weld output terminals.
Select a cable connection to match the wire polarity.
<Note>
 When welding with 2 persons using different polarities for the same base material, a
single worker must not hold 2 holders because the voltage between the 2 holders
could become high and there may be a danger.
Wire Polarity Cable Connecting Method
DC (-)
Connect the wire feeder to the negative (-) side
Connect the ground (base material) to the
positive (+) side
DC (+)
Connect the ground (base material) to the
negative (-) side
Connect the wire feeder to the positive (+) side
6. Preliminary Preparation for Welding

- 9 -
6-3. Welding Cable Connection
Warning: Electric Shock
 Be sure to stop the engine whenever touching Weld output terminals such as
when installing or removing welding cables, and when replacing the wire and
feed rollers.
 Do not connect a welding cable to any part other than weld output terminals.
<Note>
 Joint terminals and similar parts are not equipped to power cable tips at the time of
purchase.
Use insulation when installing terminals in order to prevent electric leakage.
 Make sure the crimped terminals are securely crimped and welding cables are
securely connected. Insufficient connection may result in faulty welding that
generates heat and burns the welding output terminals.
 Using this wire feeder without installing crimped terminals to the cables, but rather
with the covering peeled back and the wiring wrapped around the welding output
terminals may result in faulty connection that generates heat and burns the welding
output terminals, as well as contact with the welder main unit, causing a short circuit.
Base material
Gun
Gun trigger
connector
Work clip
Connection Diagram: Using DC (-) Wire
"+" side
welding cable
14-Pin Plug
Welding cable
Gun cable
Shield gas hose
Shield gas hose

- 10 -
6-4. Feed Roller Replacement
Replace the feed and pressure rollers to match
the wire diameter being used.
The nominal diameter of the roller is inscribed
on the surface.
Stop the welder and stop the supply of
power to the wire feeder.
Remove the spool retainer and then
remove the wire.
Release the pressure arms and open the
gates.
Remove four knurled screws.
(The knurled screws of the gates are
left-handed.)
Remove two feed rollers and two pressure
rollers.
Install the rollers in the reverse order of the
removal procedures.
Install the feed rollers with inscription of the
used wire diameter on the outside.
<Note>
 Make sure that the upper and lower rollers are for use of the same wire diameter
when assembling. Installation of different upper and lower rollers, or a roller not
appropriate for the wire diameter negatively affects feeding performance.
 Always be sure to use genuine parts when replacing parts.
6-5. Gun Connection
Fully insert the Gun connection fitting into this
wire feeder and tighten the fixing screw.
<Note>
 Use the designated Gun.
 Use of a non-designated Gun may result in
terminal damage or abnormal overheating
during welding.
6-6. Wire Setting
Remove the spool retainer and set the
wire on the spool shaft.
Release the pressure arms and open the
gates.
Feed the wire along the guide to the gun.
Close the gates, clamp the pressure
arms.
Start the welder, turn on the wire feeder
power, and press the wire feed button to
feed the wire to the gun.
* Straighten the tip of the wire to make threading easier.
Spool retainer
Wire
Loosen
Tight
en
Pressure
arm
Gates
Feed rollers
Pressure
roller
Knurled
screws
Gun
Fixing screw
Connection
fitting
Gate
Guide
Spool retainer
Spool shaft
Wire feed
button
Loosen
Pressure
arm
Tighten

- 11 -
6-7. Spool Brake Adjustment
Adjustment bolt at the center of the spool
shaft can control the brake strength to prevent
overrun.
<Note>
 If the pressure is too high, it will hinder the
spool shaft, possibly resulting in motor
overload or wire feeding fault.
6-8. Pressure Arm Adjustment
Adjust the pressure by pressure arm
according to wire thickness.
Weak pressure may result in wire slippage or
feeding fault.
The pressure value is printing on the pressure
arms.
<Note>
 Set the same pressure value f on each pressure arm.
6-9. Duty Cycle
The duty cycle is the percentage of time the load is being applied in a 10 minute period.
For example a 60% duty cycle, represents 6 minutes of load and 4 minutes of no load in
a 10 minute period.
<Note>
 Continuing to weld beyond the rated duty cycle with the rated output can result in
equipment overheating and corresponding malfunctions.
Set the pressure am as follows:
FCAW (Self-Shielded Wires) between 2 and 3
GMAW (Solid or Cored Wires) between 3 and 4
Pressure arm
Grip
Stronger
Wea
ker
Weaker
Stronger
Adjustment bolt

- 12 -
Warning: Electromagnetic Interference
 Persons using a heart pacemaker are not allowed near the welder or welding work
area while welding is being performed without the permission of a doctor.
The welder generates a magnetic field while energized that can negatively affect
pacemaker operation.
Warning: Suffocation from Welding Fume
 Always be sure to wear a fume-proof mask when welding as the fumes generated
during welding include harmful gases and dust. Also be careful that the wind
direction is not such that it will cause fumes to be inhaled and always operate the
equipment in a well-ventilated area.
Warning: Fire
 Keep any ignitable items (such as fuel, gas and paint) or inflammable items away
from the work area due to the scattering of weld spatter that occurs during welding.
Warning: Electric Shock
 Touching a charged part may result in lethal electric shock or burns.
 Do not touch the charged part of the wire, wire-feed parts, or similar charged parts
while performing welding work.
Caution: Eye and Skin Injury
 Always be sure to wear arc-proof glasses (refer to the table below), clothes that
completely cover the skin and other protective gear when welding to protect the
eyes and skin from harmful light rays generated during welding.
Standards for Arc-Proof Glasses (Japanese Industrial Standard)
Light Shielding No. 9 10 11 12 13 14
Semi-automatic
Arc Welding
Weld
current (A) 100 or less 101-300 301-500
Caution: BURNS/Electric Shock
 Always be sure to wear leather gloves, apron, shoe covers, arc-proof glasses (face
shield), safety shoes, hard hat and long-sleeve clothing to protect against the
scattering of weld spatter that occurs during welding.
 If wearing gloves, be sure to always wear gloves with dry insulation properties.
Do not wear gloves that are damaged or wet.
Adjust the voltage and wire feed speed to match the welding work performed.
7. Welding Work
Charged parts
Wire

- 13 -
<Note>
 Do not use in an area with high temperature or humidity, or an area with a large
amount of dust.
 Close the door of this wire feeder while performing welding work.
Overview of Wire Feeder Settings (CC Mode)
Wire
Diam.
[mm]
Wire Feed
Speed
[inch/min]
([m/min])
Feeder Voltage
[V] Current [A]
FCAW
(Self-Shielded Wires)
φ1.6
280
(7.1) 25.0 210
560
(14.2) 30.0 330
φ2.4 160
(4.1) 25.0 300
GMAW
(Solid or Cored Wires)
φ1.2
270
(6.9) 22.0 150
450
(11.4) 24.0 260
Welder Main Unit Settings
7-1. Display
 Wire feed speed/Amperage meter
Indicates the set value of the feed speed when the wire feed speed lamp is lit up.
Indicates the actual weld current value when the current lamp is lit up during welding.
 Welding voltage meter
Indicates the actual input voltage value when the voltage lamp is lit up.
When the 14-Pin Plug is connected, the welding voltage meter displays "- - - -" while
welding is not performed, and displays the actual weld voltage value during welding
and it will be displayed for eight seconds after you stop welding.
The actual input voltage value is constantly displayed when not using 14-Pin Plug.
Weld Mode Selector
"CV WIRE"

- 14 -
7-2. Wire Feed Speed Adjustment
Wire feeding speed adjustment dial can
control the feeding speed.
Turn the dial clockwise to increase the wire
feed speed.
Turn the dial counterclockwise to decrease the
wire feed speed.
7-3. Voltage Control
The voltage control dial functions only when
the 14-Pin Plug is connected.
Turn the voltage control dial to adjust the
output voltage of the welding power source.
Displayed Items
14-Pin Plug
Connection
Wire feed speed/Amperage meter Welding voltage meter
When no
welding is
performed
During welding
When no
welding is
performed
During welding
Connected Set value of wire
feed speed
Actual weld
current value     Actual weld voltage value
Not
connected
Set value of wire
feed speed
Actual weld
current value
Input voltage
value
Actual weld
voltage value
7-4. Wire Feed Speed Selector Switch
"High" and "Low" selector allows you to change
the wire feeding speed range.
 High: 50 to 700 [inch/min]
(1.3 to 17.8 [m/min])
 Low: 50 to 350 [inch/min]
(1.3 to 8.9 [m/min])
* Setting to "Low" makes fine adjustment
easier.
7-5. CC/CV Switch
Operate the CC/CV switch to change between
"CC Mode" and "CV Mode".
 CC Mode (Engine welders)
Adjusts (varies) the wire feed speed to
match the change in the arc length in order
to maintain a uniform arc length.
 CV Mode (Welders using a commercial
power source)
Supplies wire at a constant speed.
Wire feed speed/Amperage meter
Welding
voltage meter
W
ire feed speed
selector switch
Wire feed
speed lamp
Current lamp
Faster
Slower
Voltage
l
amp
Wire feed speed
dial
Voltage control
dial
CC
CV
Wire feed
button
CC/CV switch

- 15 -
7-6. Wire Feed Button
Use inching to thread wire when setting the wire spool or replacing the welding torch.
Voltage is not applied to the wire when feeding Wire Feed Button.
Use the wire feed speed adjustment dial can adjust the wire feed speed.
7-7. 2 STEP-Trigger Interlock Switch
Operate the switch to turn the self-holding function "ON" and "OFF".
Trigger Interlock "ON": Hold gun trigger to start welding, after the arc stabilizes, welding
will continue when trigger is released.
To stop welding, press and release the trigger.
* This function is useful when performing continuous welding.
Trigger Interlock "OFF": Arc is generated only when you hold the trigger.
Release the trigger to stop welding.
* This is useful when preforming tack welding or when you
perform welding of short length on many places.
7-8. Soft Start Switch
This function gradually increases the current
value when you start to weld.
7-9. m/inch Selector Switch
You can change the units for the wire feeding
speed between "m/min" and "inch/min".
7-10. Monitor Display
This wire feeder is equipped with an error
indicator function that indicates faults during
operation. If a fault is detected during operation,
it is indicated by the monitor lamps. When error
is detected, you must immediately stop
operation, and inspect and repair the location of
the fault.
(Refer to "8. Troubleshooting".)
 Motor overload
The motor overload lamp flashes to indicate
an overload state.
The lamp lights up if the overload state continues for five seconds or more and this
wire feeder power is cut off.
The wire feeder will perform automatic recovery approximately one minute after the
power is cut off.
 Overheating
The overheating lamp lights up if there is abnormal temperature and this wire feeder
power is cut off.
The wire feeder will perform automatic recovery approximately one minute after the
power is cut off.
Soft start switch
m/inch
selector
switch
2 S
TEP
-
Trigge
r
i
nterlock
s
witch
Motor overload
lamp
Overheating
lamp

- 16 -
Warning: Electric Shock/Injury
 Do not use the equipment if the equipment or your body is wet.
 Always be sure to disconnect the power cable when performing inspection or
maintenance.
 Do not place hands in rotating parts while operating. You could be caught in the
rotating parts.
Refer to the table below to perform inspection when the equipment is operating poorly.
If you cannot resolve a problem after inspecting the equipment, request repair at the
retail outlet where the equipment was purchased.
Faulty Operation
Symptom Possible Causes Remedy
Wire not feeding
1. Roller wear.
2. Foreign material has gotten into
the gun cable.
3. Gun tip deformation.
4. Faulty motor operation.
(Faulty cable connection)
1. Replace the rollers.
2. Clean the rollers and replace
the liner.
3. Replace the tip.
4. Check the connections of the
work clip and welding cable.
Wire speed is low
1. Wire feed speed adjustment
dial is at improper position.
2. Faulty wire feeding.
3. Gun tip deformation.
1. Turn the dial to the right.
2. Clean the rollers and gun
cable.
3. Replace the tip.
Wire speed is high
1. Wire feed speed adjustment
dial is at improper position.
2. Faulty motor operation.
1. Turn the dial to the left.
2. Repair.
Wire feeding does
not stop
1. Control board malfunction. 1. Stop the power input and
repair.
 Remove the work clip.
 Stop the power output.
Gas does not flow or
does not stop
flowing; wire feeds
1. Gas supply is off or not supplied
properly.
2. Gas valve malfunction.
3. Gas hose is cut or crushed.
4. Foreign material has gotten into
the gun cable.
5. Control board malfunction.
1. Check the gas cylinder plug.
2. Check coil voltage and
connections of gas valve.
Check conduction of coil.
Replace gas valve if necessary.
3. Clear blockage in gas hose or
replace the hose.
4. Clean the rollers and replace
the liner.
5. Repair.
8. Troubleshooting

- 17 -
Part Replacement Cycles (Rough Guide)
Affected Part Part Replacement Cycle
Gun
Gun tip Approx. 1 week
Liner Approx. 6 months
Nozzle Approx. 3 months
Wire feed unit Rollers Approx. 1 year
* The part replacement cycle varies greatly depending on use conditions.
If any of the symptoms indicated below are present, replace the parts regardless of the
replacement cycle.
Affected Part Part Symptom
Gun
Gun tip

Gun tip is distorted
 Hole has become excessively large due to wear
 Wire shavings have accumulated on hole inner
surface
Liner  Wire shavings have accumulated inside liner
 Welding wire does not feed smoothly
Nozzle  Tip connection part is visible due to wear
 Considerably damaged
Wire feed unit Rollers  Wear or chipping of knurled surface
Error Messages
Display Probable Causes Recovery Measures
Motor overload
lamp lights up
1. Foreign material has gotten into
the gun cable
2. Gun tip deformation
3. Faulty roller operation
4. Gun cable is kinked or tightly bent
5. Pressure arm is excessively
tightened
6. Spool shaft adjustment bolt is
excessively tightened
1. Clean
2. Replace the tip
3. Repair
4. Arrange the gun cable so that it
is free of kinks and tight bends
5. Adjust to the proper pressure
value
6. Adjust to the proper strength
Overheating lamp
lights up 1. Abnormal temperature 1. Wait until cool (Approx. 1 min.)
<Note>
 Maintenance of this equipment must be performed by specialized technicians.
 Always be sure to use genuine parts when replacing parts.
 When performing maintenance with doors or covers open, be sure that no other
persons can accidentally come close to the equipment.
Close doors if momentarily leaving the equipment unattended.
 A simple inspection cannot always resolve some problems. If you cannot resolve a
problem after inspecting the equipment, request repair at the retail outlet where the
equipment was purchased.